Ks-2000 Exploded Parts View

Transcript

Table of Contents Preface General Safety Information Returned Goods Procedure Warranty Introduction (KS-2000) Dry Machine (R-500) Recycle Machine (B-10) Blower Module (V-15) Vacuum Module (FB-250) Filter Box Water Tank System Generator Set Power Take Off Access Doors Control Panel Module 1 2 3 3 5 6 7 7 8 8 8 9 10 10 10 Main Power Panel Box . . . . . . . . . . . . . . . . . . . . . .10 System Operating Controls . . . . . . . . . . . . . . . . . . . 11 Panel Outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Remote Control Units KS-250 Operating Instructions 13 13 Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Settings for Wall Spraying . . . . . . . . . . . . . . . . . . . . 14 Settings for Attic Blowing . . . . . . . . . . . . . . . . . . . . 14 Attic Nozzle Assembly . . . . . . . . . . . . . . . . . . . . . . 15 KS-250 Mechanical Settings Trouble Shooting Maintenance Electrical Schematics Electrical Lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Junction Boxes . . . . . . . . . . . . . . . . . . . . Pump Cabinet Electrical . . . . . . . . . . . . . . . . . . . . . Exploded Parts List 16 17 19 24 24 25 26 27 28 KS-2000 Dry Machine . . . . . . . . . . . . . . . . . . . . . . 28 R-500 Recycle Machine . . . . . . . . . . . . . . . . . . . . . 32 V-15 Vacuum Assembly. . . . . . . . . . . . . . . . . . . . . . 35 B-10 Blower Assembly. . . . . . . . . . . . . . . . . . . . . . 37 FB-250 Filter Cabinet.. . . . . . . . . . . . . . . . . . . . . . . 39 Air Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Water Pump Assembly . . . . . . . . . . . . . . . . . . . . . 41 Water Tank Hose Reel . . . . . . . . . . . . . . . . . . . . . . 42 Pump Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Cummins Generator . . . . . . . . . . . . . . . . . . . . . . . . 46 John Deer Generator . . . . . . . . . . . . . . . . . . . . . . . 48 PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Hose Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Electrical Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Rev. Date 1/18/10 Page ii Preface Thank you for purchasing a KRENDL FIBER MOVING MACHINE. With over forty years experience in manufacturing fiber moving equipment, we have designed and built your machine with the highest quality to provide years of reliable service. This manual has been prepared to help you obtain the maximum efficiency and service from your Krendl equipment. The equipment is designed to condition and apply fibers with the utmost in dependable performance. Our primary objective is to build equipment which will provide complete satisfaction so that you may confidently recommend Krendl to others. We do not manufacture or sell fibers. Our interest lies only in the proper performance of the equipment we manufacture. We make no recommendations or guarantees concerning various fibers. CAUTION: This manual contains important information regarding the safe assembly and operation of your machine. We urge you to read it carefully and follow the instructions provided. If your questions are not answered in this manual, may we hear from you? We want you to be able to operate this unit safely and confidently. FILL IN AND RETAIN: Krendl Machine Company Telephone: 800-459-2069 1201 Spencerville Rd Fax: 419-695-9301 Delphos, Ohio 45833 U.S.A. E-mail: [email protected] Web Site: www.krendlmachine.com For your protection in the event of theft or loss, please fill in the information requested for your own records. This information will be needed for in-warranty repairs and when ordering replacement parts. You may also want to attach a copy of your invoice. Machine model number _ Serial number _ Date of purchase _ Supplier/Distributor _ General Safety Information Important: Read all instructions before operating this unit. This equipment can be potentially dangerous and must be used in strict accordance with instructions. Disclaimer Notice: The manufacturer will not be legally responsible for any injury or damage resulting from the improper use of this equipment or the failure to follow instructions. Rev. Date 1/18/10 Page 1 General Safety 1. Read this manual carefully and become familiar with your machine unit. Know its applications, limitations, and any hazards involved. 2. This machine was designed and manufactured for specific applications. Do not attempt to modify the unit or use it for any application it was not designed for. If you have any questions about your intended use or the equipments suitability, ask your dealer/distributor or consult the factory. The manufacturers' could not possibly anticipate every circumstance that might involve a hazard. For that reason, warnings in the manual and warning tags or decals affixed to the unit, are not all-inclusive. If you intend to handle, operate, or service the unit by a procedure or method not specifically recommended by the manufacturer, first make sure that such a procedure or method will not render this equipment unsafe or pose a threat to you and others. Electrical Safety • The National Electric Code (NEC) in the United States and many international electrical codes require frame and external electrically conductive parts of this machine to be properly connected to an approved earth ground. Local electrical codes may also require proper grounding of machine. Consult with local electricians for grounding requirements in your area. • Never handle any kind of electrical cord or device while standing in water, while barefoot or while hands or feet are wet. Dangerous electrical shock will result. • Use a ground fault circuit interrupter (GFCI) in any damp or highly conductive area. (metal decking or steel work) • Reference NFPA 79, 70E, or OSHA safe work practices when performing energized work procedures. Safety/Caution • Be Safe - Keep away from moving parts. • Be Safe - Make sure all guards, hopper bars, hopper extensions, and doors are in proper place before operating machine. • Be Safe - Do not remove motors or lift hopper when unit is connected to power supply. • Be Safe - Make sure motor controls and remote control hand pendant switch are in off position before connecting and turning on the power supply to the machine. • Be Safe - Make sure machine is properly grounded. Protect all electrical supply cords from sharp objects, moisture, and other potentially hazardous materials. Keep power cords in good repair. Electrical service must be performed by a qualified electrician. • Be Safe - Disconnect and lockout power supply before inspecting or adjusting unit. Generator must be off. • Be Safe - Consult a qualified technician to answer questions before attempting to operate, or injury may result. • Be Safe - Wear an approved dust mask or respirator for operator comfort and protection. • Be Safe - Emergency Kill Switch - In case of emergencies, always use red stop button located on the top and the front of the Main Control Panel. It will stop all feeding and agitation. • Be Safe - Use proper and secure clamping method for all fiber hoses to prevent uncontrolled fiber stream bursts around operator. • Be Safe - Check all pressure line connections for wear and durability to avoid potential rupture in area of operator. Rev. Date 1/18/10 Page 2 Make Sure! • Hopper is empty of foreign objects before starting. • Adequate electrical power is supplied or damage to unit will result. • Blower filter is kept clean and in place when blower is on. • Blower is turned off immediately if hose is plugged, or blower will overheat. • Blower(s) must be on, when agitators are running, or machine will bind. • Agitator motor is not run with hopper empty for more than a few minutes, or damage to seals will result. • Sprockets, chains, belts and pulleys are correctly aligned and tensioned. • Pieces of bag are not left in the machine as this can bind and stall your machine or damage airlock seals. Returned Goods Procedure IF MACHINE WAS NOT PURCHASED DIRECTLY FROM KRENDL MACHINE COMPANY, CONTACT YOUR SUPPLIER / DISTRIBUTOR. When returning products to Krendl for repair, first obtain a return goods authorization, at which time you will be given shipping instructions. The product must be shipped PREPAID: Krendl Machine Company Telephone: 800-459-2069 1201 Spencerville Rd Fax: 419-695-9301 Delphos, Ohio 45833 U.S.A. E-mail: [email protected] Web Site: www.krendlmachine.com Once the unit is received, it will be inspected. In-warranty units will be repaired and returned immediately. An estimate of repair charges will be provided for out-of-warranty units. Warranty WARRANTY Krendl Machine Company warranties new equipment only against defects in workmanship and materials for 12 months from the date of purchase. Liability in all events is limited to the purchase price paid. Liability under the aforesaid warranty is limited to replacing or repairing any part or parts which are defective in materials or workmanship and are returned to our factory, shipping costs prepaid. No warranty, express or implied, other than the aforesaid warranty is made or authorized by Krendl. Krendl Machine Company shall not be liable for any personal injuries or damage to property caused directly or indirectly through the use of this equipment or costs associated with loss of production. Note: Special job circumstances incurring costs for specialized repair and next day delivery of parts will not be reimbursed by the manufacturer unless authorized by factory. Rev. Date 1/18/10 Page 3 WHAT THIS WARRANTY DOES NOT INCLUDE Warranty This warranty shall be void if the product has been subjected to misuse, negligence or accident, or if the product has been repaired or altered outside of our factory. This warranty does not cover the free replacement of parts that become inoperative because of wear, nor does it cover the labor costs of replacing parts by someone other than the factory. This warranty does not cover free adjustment of this product if this product was adjusted by the purchaser. Information and design disclosed herein was originated by and is the property of Krendl Machine Company. We reserve the right to proprietary design, manufacturing, production and sales thereto and to any articles disclosed therein, except to the extent that such rights are expressly granted to others in writing. Rev. Date 1/18/10 Page 4 Introduction The Modular System contains six distinct parts: a dry hopper machine (KS-2000), a recycle machine (R-500), a 10 hp blower system (B-10), a 15 hp vacuum system (V-15), a filter system (FB250) and a generator. Illust. 1 Objective: to familiarize spray technicians with the features and use of the KS-250 system. A 3” hose connects the KS-2000 dry machine and the R-500 recycle machine. (Illust. 2A) When the system is used for spraying walls(i.e., both machines are running) the blower system (B-10) blows the dry cellulose from the KS-2000, through the 3” connecting hose and into the R-500 airlock. As the material passes through the R500 airlock, it blends with the recycle fiber metered from the R-500. This homogeneous blend of dry material and recycled material continues up the hose and out the wall spray nozzle. Both machines can be adjusted independently for material feed. In the wall spray mode, all the air is coming from the B-10, thru the KS-2000 and R-500 and discharging out the hose. The Vacuum System (V-15), provides a fast method of recycling material from the job site to the R-500 machine. This recycle is metered back into the spray system. The filter box (FB250) separates the fine dust particles from the air discharge. This provides a dust free environment inside and outside of the truck. Viewed from inside truck (Illust. 2A) Rev. Date 1/18/10 Page 5 Viewed from outside truck (passenger curbside) (Illust. 2B) KS-2000 The KS-2000 unit is located inside the truck on the passenger’s side. The airlock faces the wall, and is accessible through an 18” x 45” door located on the truck exterior. (Illust. 3) This side door should remain open when the machine is operating for open blow attics. The maintenance side of the machine faces the inside of the truck for easy access. Illust. 3 (See Maintenance section pg.18 for better access.) Located at the rear of the truck are the controls for blower air, dry fiber feed rate, and the main electrical panel for selection of functions. Airlocks The airlock of the KS-2000 is accessible through the 18” x 45” door. (Illust. 3) When blowing attics, the 3” or 4” outside blowing hose should be connected directly to this airlock. When spraying walls, the 3” outside blowing hose should first be connected to the R-500 airlock at the 3” elbow connected at the R-500 airlock output. (Illust. 4) The 3” inside The airlock of the Krendl KS-2000 is accessible through the 18 x 45 door. connecting hose connects directly into the back side of the R-500 airlock from the KS2000 machine. The dry material passes through the airlock of the R-500 (which is running while spraying) and the recycle blends into the flow of dry material. Hopper (Facing machine from inside truck) An extension hopper is located on top of the KS-2000. The extension hopper on the KS-2000 provides a capacity of twelve 30-pound bags of insulation material. For best operation and holding capacity, bags should be slid into the machine so they lay Bags should not be broken up. They should be slid into the machine so that they lay flat. flat, rather than broken up. Rev. Date 1/18/10 Page 6 R-500 The R-500 is accessible through the 18” x 45” door on the passenger side of the truck. (Illust. 4) Feed adjustments can also be made at this location with the crankgate handle. On top of the R-500 is a canister, or sealed tank top. Together, the machine and the canister provide approximately 25 cubic feet of holding tank capacity for the recycle (3-4 bags). Illust. 4 The unit is sealed with gaskets to prevent dust from leaking out and entering the truck. Inside the canister, a stainless steel mesh screen filters out small particles. A wiper edge keeps this screen open to air passage. (IMPORTANT: At the end of each day, open the access door of the canister and remove fiber build-up from stainless steel mesh screen. This will prevent The Krendl R-500 is accessible through the 18x45 door on the passenger side of the truck. any loss of vacuum power and reduce pressure build-up inside canister.) An agitation system inside the canister prevents material from bridging. On the inside of the canister is a paddle wheel sensor (bin level indicator), which shuts the vacuum off when the canister becomes full of recycle. As material is used, the sensor begins to rotate again and turns the vacuum system back on. A timing mechanism in the main electrical panel box delays starting so that the motor will not short-cycle. During operation, the vacuum automatically turns on and off as needed to keep the hopper from overloading and packing the canister. The clean-up crew should keep a close eye on the level of material in the hopper, and not allow it to run empty. During spraying operations, the hopper can empty out in 1 to 2 minutes. The clean-up crew should stay The clean-up crew should stay about 10 feet behind the spray tech. about 10 feet behind the spraying. When the vacuum system starts, the crew should begin vacuuming before the hopper empties. B-10 The B-10 under the truck blower module (located on the drivers side of the truck) consists of a 250 CFM, 6 p.s.i. rotary positive blower. This unit supplies the necessary air pressure for open blowing and spraying fibers over 150 ft. The blower system is protected with a check valve, pressure relief valve, and air filter components. Illust. 5 Rev. Date 1/18/10 Page 7 V-15 The V-15 under the truck vacuum module (located on the rear passenger side of the truck) draws in recycle material from the job site and delivers it directly into the R-500 recycle machine canister. Once the recycle material has been deposited into the canister, the air passes through the stainless steel mesh screen in the R-500 canister, where it is pre-filtered, then it passes to the FB250 filter cabinet where it is further filtered and exhausted outside the truck. Illust. 6 FB-250 The FB-250 filter system (located inside the truck on the driver’s side) consists of an air tight box with a filter bag. The filter bag provides a filtration system which separates the fine dust particles from the air discharge outside the truck. This provides a dust free environment inside and outside of the truck. Note: Empty the filter bag as needed. Illust. 7 Water Tank System The water tank system consists of a 230-gallon water tank and a cabinet which contains the water pump, heaters, hose reel, hoses, and controls. (Illust. 8) The water tank is covered by two inches of rigid board foam insulation inside of a metal frame. This frame facilitates securing the tank to the floor and stabilizing it to the front of the truck with the mounting bracket. In the center of the tank is a tube that acts as an air vent. This tube equalizes the pressure in the tank when filling or while running the pump. It also doubles as an overflow pipe, extending down below the bottom of the truck box. Built into one end of the tank (passenger side) is a pump cabinet. This contains the water pump, pressure line, hose reel, a submersible heating element with thermostat, Illust. 8 and a pump cabinet heater with thermostat. Note: In freezing temperatures attach power cord to outlet below pump cabinet, and flip toggle switch inside pump cabinet to “line”. This will maintain a higher temperature inside tank and pump cabinet. Pump Cabinet The supply (suction) line from the tank to the pump has a clear bowl filter with an 80-mesh screen, while the return line runs directly back into the tank. This arrangement allows the system to operate for long periods of time Rev. Date 1/18/10 Page 8 with the nozzle turned off without causing any pump damage. Both suction and return lines have shut-off ball-valves and quick couplers which allow the pump to be removed without first draining the water tank. The pump cabinet also contains a drain valve and hose which when pulled out of the cabinet, protrudes about 6” beyond the door. This could also be used for washing hands at the end of a job. (There is also a valve on the fill hose which must be opened when filling tank.) The combination of 2” foam insulation surrounding the tank, along with the submersible water heater and cabinet heater, allow the use of this system in subzero weather conditions. (Note: Put pressure hose through floor to keep door closed tight in subzero temperatures.) Illust. 9 Pump Controls Controls for the water pump system include a Start switch, a pressure-adjustment knob, and a water pressure gauge. (See illust. 9) The Start switch is located directly on the pump. The brass, hexagon-shaped knob located near the cabinet door adjusts system water pressure, while the nearby gauge allows precise monitoring. Water Pressure When wall spraying, system water pressure should be adjusted as follows: • For a 2” nozzle, use water pressure of approximately 150 psi. • For a 2 1/2” nozzle, pressure will range from 200 to 250 psi depending on the volume of material being sprayed. Generator Set Option Power for the KS-250 is delivered by a 60KW 3-phase generator, which is driven by a diesel engine. Note: only factory approved and installed generators can be used to enforce warranties. The generator features an automatic safety system to shut down in case of a low oil alarm or high temperature. It also sports a quiet, industrialgrade muffler, with rubber base-mounts to attach to the engine base for extra sound and vibration control. The diesel generator is surrounded by a special air tight metal cowling with outside venting, which directs intake air through the engine radiator for cooling, and protects the unit from dust. The cowling contains a side door, which allows easy access during oil and filter changes. Though the cowling is hard-mounted to the floor and wall, it can be easily removed to allow more complete engine or generator access. Fuel Pump The diesel engine utilizes a fuel pump, making it possible to mount the fuel line to the existing diesel fuel tank or to an optional DOT-approved tank. Diesel Generator Controls and Starting At the radiator end of the generator (rear of truck) is a switch box that contains a key ignition and a push-button. (See illust. 11 on page 10) The push-button must be held in and the key turned clockwise to activate the Starter. Do Rev. Date 1/18/10 Page 9 not release the push-button until the generator is up to speed. The switch box also contains an hour meter, which is used to measure the run time of the engine. Note: Oil changes are determined by the number of hours the engine has been running. Power Take Off Generator Option Power for the KS-250 is delivered by a 60KW 3-phase generator, which is driven by a power take off. Note: only factory approved and installed generators can be used to enforce warranties. The generator is surrounded by a ventilated enclosure that provides protection from moving parts. The enclosure is mounted to the truck and can be removed to allow access to the power take off pulleys, belt, and ventilation fan. When engaging power take off, put truck in neutral and engage parking brake. Located inside the truck cab is a PTO ignition switch. To engage power take off, depress the clutch, turn PTO ignition switch to the ON position, release clutch slowly and allow PTO to come up to speed. To disengage power take off, depress the clutch and wait 15 seconds until the PTO stops turning, turn PTO ignition switch to OFF position, and then release the clutch. Access Doors Four access doors are located on the passenger side of the van body. (Illust. 10) The first door (18” x 45”) allows access to the airlocks for the KS-2000. The second door (18” x 45”) allows access to the R-500. The third door (48” x 92”) allows access for quick loading of fiber. The fourth door (18” x 45”) allows access to the water pump hoses and controls. There is one access door located on the driver’s side of the van body. The (36” x 48”) louvered access door provides cooling air ventilation to the generator while allowing quick access for service. (Illust. 10) Control Panel Module The Control Panel Module is located at the back end of the KS-2000 machine, and is accessible from ground level at the back of the truck. (Illust. 11) The Control Panel Module contains the Main Power Switch and the system operating controls. Main Panel Power Box K S-250 DRY M ODE REC YC LE MO DE VAC UUM M ACHINES RE MO TE On top of the Main Panel Power Box is a red Kill Switch. (Illust. 11) When pushed in, this switch shuts off all power to the machine. In case of a safety-related emergency, foreign material being dropped into the hopper, or if any strange noises are heard from the equipment, push this Kill Switch to immediately shut down the system. (IMPORTANT: Do not open panel Rev. Date 1/18/10 (Illust. 11) Page 10 box until main power disconnect is locked out and generator is off.) A second Kill Switch is located on the face of the control panel on the left side. (See Illust. 13 on page 11) This switch performs the same job as the one located on top of the box: it shuts down the entire system in the event of an emergency. The top switch is positioned for easy access from inside the truck, while the switch on the panel is positioned for easy access from the ground. • To engage the Kill Switch, push the red button. • To disengage the Kill Switch, turn the red button until it pops back out. • The green Power/Reset button must be pushed after resetting any Kill Switch to resume power supply. (See illust. 13 below) On the upper left side of the Main Power Panel Box is a Disconnect switch. (Illust. 12) This switch shuts down all power inside the Main Panel Box. The Disconnect switch must first be turned Off (“O” shows in the indicator window) before turning off the generator and it must remain off while generator is restarted. This will help protect the electrical system from low voltage when generator is coming up to speed. Both the disconnect switch and the Generator must be shut-off, before the panel box door can be opened. Only qualified, trained personnel should access this box. Once the panel box has been closed, the Disconnect switch must be turned back to On (“I” shows in the indicator window) and the green Power/Reset button pushed before power will be restored, and the system can begin operation. Be sure to retighten the two screw brackets on the left side of panel to prevent water and fiber from leaking into the box. Just below the Disconnect switch is an alarm. (Illust. 12) This alarm will sound for a few seconds whenever the machine is turned on; and before agitators move. Warning! When the alarm sounds, be sure that all hands and clothing The Kill Switch shuts down the entire system in the event of an emergency. ST-250 DRY MO DE RECYCL E MO DE VACUUM MAC HINES REM OTE (Illust.12) KS-250 are clear from the machine, since the unit is about to turn on. System Operating Controls At the bottom of the control panel Module are the operating controls for the Modular System. (Illust. 13) These include: • a red, push-button-type Kill Switch, • a green Power/Reset button, • two indicating lights (‘green’ Power On and ‘orange’ Overload OK), DRY MODE RECYCLE MODE VACUUM MACHINES • two Mode selector switches, (KS-2000/Dry Mode, R-500/Recycle Mode) • a Machines selector switch, (Open Blow, Recycle, Wall Spray) • a Vacuum switch, Rev. Date 1/18/10 The System operating controls. (Illust. 13) Page 11 Power/Reset Button The green Power/Reset button turns on the Control Panel. After starting the engine, the Power/Reset button must be engaged. It is also necessary to reset the system after any Kill Switch has been engaged. (Illust. 13) Mode Switches There are two Mode switches (see illust. 13 on page 11): • The KS-2000 switch operates the Dry Machine. • The R-500 switch operates the Recycle Machine. Each Mode switch contains four settings: • Manual: Agitator/Blower (On/Off) • Manual: Blower On/Off • System off • Remote (using either the corded remote or the radio control remote) When wall spraying, turn both the KS-2000/Dry Mode and the R-500/Recycle Mode switches to Remote, while setting ‘Machines Switch’ to Wall Spray. When blowing attics, turn the ‘Machines Switch’ to Open Blow. This will prevent the recycle machine from running while operating the dry machine and blower with remote control. Machines Switch The Machines switch makes it possible to use each machine independently, or to operate both machines together as a system (wall spraying). This switch has three settings: (See illust. 13 on page 11). • Open Blow Dry (KS-2000) • Recycle (R-500) • Wall Spray (R-500 & KS-2000) Vacuum Switch This switch turns the vacuum system on and off. (Note: If Vacuum does not turn on when activating Vacuum Switch the canister may be full.) Fuse Protection - Breakers The (4) 120 volt outlets located at the bottom of the control panel, the water pump and inputs and outputs of transformers are protected by manual breakers located inside the control panel on the upper righthand side. (Illust. 14) The fuse protection - breakers. (Illust. 14) Blower Controllers Located at the rear of the truck at the base of the KS-2000 dry machine; and accessible from the ground, are two different sized air by-pass valves. These valves provide for accurate control of blower air. The lower (larger) valve is for a general, (approximate) control setting of the air in the system. The upper (smaller) valve with a pointer gauge is for finer, specific adjustments in the air stream. Rev. Date 1/18/10 Page 12 Panel Outlets At the top right of the panel Box are a series of breakers which protect the pump and the four 120V outlets. (See Illust. 14 on page 12) At the bottom right of the Panel Box are a series of outlets (Illust. 15): • one remote outlet, • and four 120V outlets. REMOTE Remote plug-in The KS-250 panel outlets (Illust. 15) Remote Control Units Wireless Radio Controller The wireless radio controller contains three control switches: • Blower/Feed • Blower (only) • Off When switching from Blower/Feed to blower you do not have to push Off. Simply push Blower and the control will automatically switch the machine to air-only while the blower continues to run. When the manual switch on the control panel is being used, the remotes will not work. Corded Controllers One corded remote control pendant, provided with the machine, can be used instead of the wireless radio system. These corded controllers have only three functions: • Blower/Feed • Off • Blower (only) KS-250 Operating Instructions Hoses The normal recommended length of hose is 150 feet. Longer lengths of hose increase back pressure and decrease the material flow rates. Machine settings will vary with longer hose (i.e. more air, less feed). Additional lengths of hose can be added if necessary to reach a distant area. After completing these sections, remove extra hose to speed up production. Recommended hose sizes: Vacuum: 4” I.D. smooth bore hose (150 ft. maximum) Open Blow & Stabilized: 3” I.D. open blow attic Note: 4” can also be used and may increase efficiency when using stabilized. Using a longer hose Wall Spray: 3” I.D. x 150 ft. long connected decreases spray pressure and velocity. to 2 1/2” I./D. x 12 ft. (light weight hose) for all cavity spray. Rev. Date 1/18/10 Page 13 Wall Spray Machine Settings • Locate the starter panel at the radiator end of the diesel generator. Feed gate settings may vary from one machine • Hold the toggle switch On (this starts the oil circulator). to another. • In cold temperatures, turn the key counterclockwise to the Glow Plug position for 5 to 10 seconds to preheat the engine. • Turn the key clockwise to Start the engine. (Make sure the main disconnect switch is off.) Note: starting switches and/or buttons may vary with different generators. • At the main Control Panel, set the KS-2000/Dry Mode switch to Remote. • Set the R-500/Recycle Mode switch to Remote. • Set the Machines switch to Wall Spray. • Turn the Main Power Switch ON. • Press the green Power/Reset button at the control panel. (‘green’ power light ‘on’) • Turn on vacuum switch. Air and Feed Settings (Initial) 150’ Hose Length • For initial setting, open the air by-pass valve to 1/2. (For fine-tuning or adjustment, open or close the small valve.) • Open the feed gate on the KS-2000 to 4 1/2” or 5” on the scale gauge viewed from inside aisle of truck. • Open the feed gate on the R-500 to 5” on the scale gauge viewed from outside access door of truck. Note: this setting could vary from machine to machine. • For first time use, begin with a low feed setting, then gradually increase until proper spray is achieved. Note: Never use a combined setting that equals more than 10”. The Recycle airlock will plug. Attic Blowing Machine Settings for Attic Blowing • Locate starter panel at the radiator end of the diesel generator. • Hold toggle switch On (this starts the oil circulator). • In cold temperatures, turn the key counterclockwise to the Glow Plug position for 5 to 10 seconds to preheat the engine. • Turn the key clockwise to Start the engine. (Make sure the main disconnect switch is off.) Note: starting switches and/or buttons may vary with different generators. • At the Main Control Panel, set the KS-2000 Mode selector switch to Remote. • Turn the Vacuum switch to Off. • Set the Machines selector switch to Open Blow. • Turn the Main Power Switch ON. • Press the green Power/Reset button at the control panel. (‘green’ power light ‘on’) Air and Feed settings (stabilized) 150’ Hose Length • Close both air by-pass valves to direct all the air into the attic hose. Note: If dry is being blown without Internal Wetting System, lower air setting may reduce dust. Note: Different material grinds will require different settings. Rev. Date 1/18/10 Page 14 To begin blowing attics, turn the Remote cord switch or Wireless Radio Control Feed switch On. To stop the material feed, switch or push the Blower button Off. The feed and water (see Attic nozzle assembly below) will automatically turn off, while the air should continue until the material stops flowing. (Note: Machines selector switch should be on “Open Blow” to properly actuate attic nozzle/internal wetting system) Do not shut the blower off until all material has stopped flowing. Attic nozzle Assembly/ Internal Wetting System When blowing attics with a 3” hose using stabilized product, use the expansion hose assembly. This assembly consists of (in the sequence given) (illust. 16) • 10’ piece of 3’’ hose, • a reducer tube (3” up to 4”), • a 12” piece of 4” hose, • an attic nozzle (water tips eject water in the direction of material flow), • 10 feet of 4” hose, and • a reducer tube (4” down to 3”). When blowing attics with a 4” hose using stabilized product, use the expansion hose assembly. This assembly consists of (in the sequence given) (illust. 16) • 10’ piece of 4’’ hose, • a reducer tube (4” up to 5”), • a 12” piece of 5” hose, • an attic nozzle (water tips eject water in the direction of material flow), • 10 feet of 5” hose, and • a reducer tube (5” down to 4”). (Illust. 16) Positioning the Attic Nozzle on the KS-2000 • Connect (and clamp) this hose assembly to the KS2000 airlock. • Place the attic nozzle assembly onto this hose making sure the jets are directed with the material flow • Hook the remaining hose to the attic nozzle assembly. • Connect the high pressure hose from the hose reel (remove the wall cavity spray nozzle) to the Internal Wetting module (using a quick-coupler connection) located near pump base. • Connect the hose from the Internal Wetting Module to the attic nozzle on ground. • Machines selector switch to ‘Open Blow’. Make sure the cord on the Internal Wetting module is plugged into the 120V outlet on the small junction box inside pump cabinet. When the KS-2000 is turned on, the water will automatically turn on. When the feed is turned off, the water will auto(Illust. 17) matically turn off. Rev. Date 1/18/10 Page 15 Cleaning the Attic Nozzle Near the end of the job (or every 50 bags), and while the machine is still operating, tap the internal wetting system hose firmly to clear out sludge. Begin tapping the hose about 4 feet down line from the nozzle, and continue moving towards the nozzle. After Completion of the Attic • Remove the water harness. • If the nozzle will not be used until the next day or longer, leave the nozzle uncoupled and water harness off to properly dry out. KS-250 Mechanical Settings SHREDDER ASSEMBLY: This unit is supplied with a shredder assembly; airlock/agitator speeds and is preset at the factory. No further sprocket setting speeds are needed, as this system will accommodate most fibers and applications. However, the shredder direction can be adjusted as described below. KS-250 Trouble Shooting SHREDDER ADJUSTMENT: (Illust. 18) Unidirectional Rotation (See illustration 18) is preferred as an all-around setting for a combination of materials and applications. This setting provides for the greatest coverage and best control of the fibers in wall cavity spray, commercial spray, internal wetting (stabilized) and open blow applications. (Illust. 19) Center-Down Rotation (See illustration 19) force feeds the fiber into the airlock at a faster rate. This direction is preferred for the greatest production of various fibers in an open attic blow application although coverage may decrease. Rev. Date 1/18/10 Page 16 KS-250 Trouble Shooting KS-250 Trouble Shooting TROUBLE SHOOTING Problem Corrective Action 1) Overload Ok light (orange) is off. (Illust. 20) • Check generator - must be running • Check Main Disconnect On • Vacuum, Dry Machine, Blower, or Recycle horizontal and vertical agt. motors may have overheated. Wait a few minutes to cool down. - Starters should automatically reset and orange light will illuminate. (Except vacuum starter which must be manually reset) (Press ‘green’ power button to restart) ST-250 • If ‘orange’ light does not illuminate...Vacuum thermal overload tripped. Turn off power at Disconnect switch. DRY MODE RECYCLE MODE VACUUM MACHINES REMOTE CONTROL OUTLET Open Main Panel box, press red reset bar on lower part of large starter. (C-11) (See electrical on page 24) (Illust. 20) • Light burned out. Turn R-500 or KS-2000 mode switch to Manual, Blower/Airlock. If machine runs, light bulb needs replaced. 2) Power light (green) does not turn on when Power button is pressed. (Illust. 20) • Kill switch(s) actuated; twist to release. • Make sure overload OK light is ON (see #1) • Light burned out. Turn R-500 or KS-2000 mode switch to Manual, Blower/Airlock. If machine runs, light bulb needs replaced. 3) Remote doesn’t work. • Check both Dry and Recycle machine Mode Switch to be sure they are in Remote Position. (Illust. 20) • Make sure machine will run manually. • Check the 1 Amp transformer breaker. (Illust. 20) • Check remote control cord for continuity. 4) Wireless Remote doesn’t work. • Make sure Wireless is plugged in and there is 110 Volt power. • Try corded remote to confirm wireless Remote malfunction. If corded Remote doesn’t work, see problem #3. • Replace batteries in transmitter. Rev. Date 1/18/10 Page 17 Problem Corrective Action 5) 110 Volt Outlets do not work. • Make sure generator is on. • Make sure Main Disconnect Switch is ON. (see illust. 20 on page 17) • Check Circuit Breakers. (see illust. 20 on page 17) 6) Blower does not work. • Check main blower starter and manual thermal overload • Make sure ‘orange’ light and power ‘green’ lights are on. (see illust. 20 on page 17) 7) Recycle or Dry Machine Airlock doesn’t turn. • Check to make sure access doors are closed and depress interlock switches. (Illust. 21) • If R-500 or KS-2000 motor attempts to turn or chain jumps, airlock could be plugged. Turn machines switch to Recycle. Turn blower on High. Turn Recycle and Dry Machine Mode Switch to blower and check for air coming out of either airlock. • With blower running on high (valves closed): jog each airlock to clear out debris. (Illust. 21) • Check recycle canister - full. (if full, unit will not run) 8) Vacuum doesn’t start. • Bin level paddle clogged or restricted inside Recycle Machine canister. (Illust. 22) Jog by hand to release. • Make sure the bin level indicator plugged into outlet at (Illust. 22) junction box. • See problem #2. 9) Vertical Agitator on 500 recycle canister doesn’t work • ‘Limit switch’ must be depressed at access door on canister • Check manual reset on motor starter in panel box. • Check motor cord plugged in below Main Panel Box. 10) Loss of air pressure. • Check pressure relief valve located on positive displacement blower. Unscrew entire valve and remove screen cap. To increase pressure hold nylon nut with 1/2” wrench and cap screw with allen wrench and turn clockwise. • Check all hose clamps from blower to machine for tightening. Rev. Date 1/18/10 Page 18 KS-250 Maintenance Daily • Empty fiber from recycle unit at end of day. • Check for excessive fiber build-up on recycle canister screen and scrape screen with a wire brush to remove any buildup. • Check fluid levels (oil and coolant) on generator and clean filter. • Close slidegates of Dry and Recycle Machines to prevent buildup of material in the slidegate track. • Empty bag from FB250 Filter Canister. Weekly • • • • • • Remove blower filter and blow with compressed air. Visually check chain tension on all drive systems. Clean out inside vacuum chamber. Grease vacuum and PTO shaft bearings with high speed grease. Blow off all motors. Blow out radiator and generator with compressed air. Monthly • • • • • Check vacuum motor pulley and belt tension. Check blower motor pulley and belt tension. Check and/or replace filter media in filter canister on blower module. Retighten nuts on PTO gear housing, which can loosen due to vibration. Check PTO pulley and belt tension. Quarterly • • • • Grease all bearings with high speed grease. Check condition of airlock seals. Check all hoses and connections for leaks. Generator maintenance every (250 hours) - Check filters (air & fuel) and change oil and oil filter. KS-2000 Maintenance Note: When servicing individual components of this system, the separate modules can be easily accessed by removing the “floor” bolts from inside aisle of truck and sliding unit away from the truck wall!! (When servicing the KS-2000 airlock seals, be sure to remove any hoses, cords, or other attachments first.) (Illust. 23) Periodic preventive maintenance will add years of life to your equipment. Reviewing the information in this manual will go a long way in reducing downtime and lost income. Flip hopper up for easy maintenance of lower base unit. (Illust. 23) Remove side screen guard of machine. Loosen idler sprocket and remove (2) two vertical drive chains. Make sure crank handle is in downward position. Release hold down bolts at airlock end of machine and lift hopper back gently until it rests safely on the floor. (Note: The upper hopper may have to be removed before flipping up the agitator/hopper unit. This will allow greater clearance when flipping agitator/hopper unit upward.) Rev. Date 1/18/10 Page 19 Airlock: (Seal Replacement) The purpose of the airlock seal is to trap air and fiber until it rotates 180O to the 6:00 o'clock position. At this point, fiber is pushed by air from the blower, out of the chamber. Worn or damaged seals allow air and fiber to escape back into hopper, thus reducing production and coverage. When it is necessary to replace seals, follow these directions: Remove chain and use pipe wrench on shaft end to rotate airlock rotor. Airlock rotor plates that are damaged (bent) will need replaced. (Refer to Rotor Plate Replacement below.) Take out rubber seal by removing seven plate fastening bolts and nuts and top plate. The base plate will remain attached to airlock shaft. To install a new seal, reverse procedure. Seal should be inserted tight against the back base plate, pressing the lower tabs of the seal down under the adjacent seal with a flat blade screwdriver. (See illustration 24) Make sure all bolt holes are aligned while each side of seal is equally pressed against the end plates, before tightening bolts. Seal should be bent backwards for clockwise rotation. (Illust. 24) (Illust. 25) Rotor Plate Replacement: 1.To check plates for proper angle, measure distance between outer edge of metal plates. (Illust. 24) This measurement should be 4 3/4". Measure all six plates and replace as needed. 2.Remove damaged baseplate assembly from shaft using ratchet drive wrench with extension and 1/2" socket. 3.Check seal for wear and damage. (Installing seal and top plate on the bench is quick and easy). Remove bolts from plate assembly and replace with new seal. Make sure seal and top plate are assembled on correct side of base plate before assembling in airlock. Seal should press backward towards top plate when installed correctly into airlock chamber. (Illust. 24) 4.Install the rotor plate assembly into the airlock. The airlock runs clockwise viewing it from the sprocket drive shaft. (Illust. (Illust. 26) 24) Align the base plate with holes on airlock shaft using a (Entire rotor plate assembly may be tapered punch. Caution: Do not mount rotor plate backwards. removed and replaced. This procedure If installed improperly, damage to seals will result and put Rev. Date 1/18/10 maybe easier than replacing just the seals.) Page 20 undue stress on agitator motor. This causes overheating and poor production. Seal should be bent backward to allow for a clockwise rotation of rotor. 5.As rotor plate is installed, press bottom tab of seal under adjacent seal with flat blade screwdriver. (See illust. 24 on page 20) Chain: (Adjustment) (#50 Nickel Plated) A smooth operating chain drive should have a slight sag on the idler side of the chain. New chains should be installed under slight tension as they will elongate a small amount due to seating of pins and bushings during the first few days of operation. Chain should be kept in good condition by proper lubrication (use dry film lubricant Dow 321) and occasional cleaning. Soaking chain in container of 10 weight oil will provide for internal lubrication of pins and bushings. However, excess oil must be drained and wiped away as excessive lubrication will cause fiber accumulation on chain. Worn out chain should be replaced. When chain is replaced, worn sprockets should also be replaced, preventing further damage to new chain. Sprockets: Check Sprockets For Wear. Misalignment and/or loose sprockets and improper chain tension causes the premature wear of chain and sprockets. All sprockets, except speed reducer and idler sprockets, have been secured with a medium grade Loctite (general purpose thread locker), to prevent gradual movement. The set screws and key are also inserted with a medium grade Loctite. If sprocket is difficult to remove, it may be heated with a propane torch to loosen. Caution: Do not overheat sprocket or damage to bearing will result. A pulley or bearing puller can then be used to remove the sprocket and key. Replace new sprocket on shaft with key and medium grade Loctite applied to shaft. Align sprocket with corresponding sprocket, using a straightedge placed along face of teeth and tighten set screws. Bearings: Agitator Bearings in hopper are prelubricated, double-sealed, self aligning ball bearings. Some bearings do not have grease fittings and are lubricated for life. Others have grease fittings and should be periodically lubricated. At least every 3 months. If bearings produce noise or heat (too-hot-to-touch), the bearings should be replaced. Agitator Bearing Replacement: Spray area with rust penetrant (WD-40). Remove sprocket (See SPROCKET section above). Remove the two bolts from bearing flange and outer flange from bearing insert. Loosen set screws on bearing hub at each end of agitator shaft. Since all set screws are installed with a medium grade Loctite, a propane hand torch maybe used to assist in removing them. Do not overheat unit, causing shaft to expand. Using a rubber mallet, drive agitator shaft an inch in one direction, creating a space between hopper and bearing unit. A bearing puller can then be used to remove the bearing. Eliminate any metal burrs from shaft with file and install new bearings with felt seals. Use a medium grade Loctite on set screws before securing bearing to shaft. (Check shaft diameter before ordering bearings) Rev. Date 1/18/10 Page 21 Airlock, Vacuum, Shredder and (drive side) Agitator Bearings are prelubricated, double sealed, self aligning ball bearings. Lubrication is required at three month intervals of normal running time, or sooner if bearings produce a noise or become too-hot-to-touch. Relubrication at the grease fittings is done with a lithium base grease conforming to a NLGI GRADE TWO consistency. (Note: Make sure a high speed / high temperature grease is used on vacuum bearings.) The grease should be pumped in slowly until a slight bead forms around the seals. This bead, in addition to acting as an indicator of adequate lubrication, provides additional protection against the entry of foreign matter. Important: If a slight bead does not form indicating a failure of lubrication or if bearing shows signs of wear, replace bearing. Airlock, Shredder, and Agitator (drive side) Bearing Replacement: Remove four bolts from airlock bearing flange (two bolts from shredder bearing flange) and follow steps above for agitator bearing replacement. Speed Reducer: (Lubrication) Periodically check oil level in reducer. Do not lay machine on its side as lubricant from unit will drain from vent plug. If speed reducer malfunctions because of improper oil level or type used, warranty is voided. Oil seals at input and output drives are considered to be replaceable maintenance items and can affect oil level. These are available at power transmission distributors. Your speed reducer has been filled with a heavy synthetic lubricant (Klubersynth UH1 6-460). Consult speed reducer manufacturer's manual for lubricant replacement intervals. Agitator Motor: If agitator motor runs hot, activating the manual reset located in main panel box, or if unit does not run properly, refer to troubleshooting sections of manual. The agitator motor should start quickly and run smoothly. If not, shut motor off immediately and check the cause. Low voltage, incorrect power supply, bad bearings, or misconnected wiring could cause motor failure. These conditions void the motor warranty. Overload conditions can be detected by checking the electrical current (amperage) compared with nameplate current (amperage) located on the body of the motor. Agitator Motor Replacement: Remove conduit and wire connectors from wires inside conduit box on motor. (tag wires for easy hook-up) Remove drive chain and flip hopper up as described at the beginning of General Maintenance section. Place a support block under motor to reduce stress while removing four reducer flange bolts with a 9/16" socket wrench. (If rear bolts are difficult to reach, remove reducer unit from lower frame for better access.) Pry motor from speed reducer a slight distance, using two large flat blade screwdrivers placed in the slots (180O apart) where they join together. Pull motor unit straight away from speed reducer, retaining key. (See illust. 27 on page 23) Before installing replacement motor, refer to motor nameplate. Check connection of new wires for correct voltage (low or high) and PROPER ROTATION of motor output shaft (clockwise facing output shaft). Rotate keyways of motor shaft and quill (input) of speed reducer to 12:00 o'clock position. (To turn speed reducer shaft, chain on output of speed Rev. Date 1/18/10 Page 22 reducer will need to be removed.) Assemble the key 3/4 inch in from the end of the motor shaft and coat motor shaft with anti-seize compound. Align and insert the motor shaft carefully into the input quill. (A flat blade screwdriver may be helpful to keep key in place as motor shaft is inserted.) Secure to flange with four hex bolts. Caution: If the motor does not readily seat itself, check to determine if key has moved axially along motor shaft, causing interference. Tightening motor to reducer with excessive pressure against key will cause premature bearing failure and overheating of motor. Connect motor cord to Junction Box and check for correct rotation of speed reducer output shaft (clockwise). Reconnect drive chain and assemble unit for manual operation. (Illust. 27) Blower Module: Motor and Blower Periodically remove Blower Filter and vacuum any material that has accumulated inside of blower box and around blower motor. Blow out any remaining debris around motor and intake orifice of fan with compressed air. This will extend the life of the blower significantly. Blower Filter life can be extended by occasional removing and back or reverse blowing through with compressed air. Filter should be replaced periodically depending on use. If blower produces noise or heat, refer to troubleshooting section of manual. Check belt tension and possible air leaks in the hose line to the machines. Check for secure clamps. Line pressure can be increased if needed by removing cap of pressure relief valve and turn allen head screw clockwise. Check and/or change oil (PneuLube) in the blower pump housing. Refer to owners manual (separate component literature.) The internal blower assembly mounted to ‘C’ channel base, is removed from box enclosure to change oil. Drain ports are located at the rear of blower housing. Adequate electrical conduit is available to remove this unit without detaching electrical connections. (Illust. 28) Rev. Date 1/18/10 Page 23 KS-250 Electrical Schematic Electrical Diagram: Periodically, disconnect machine from power source and check all electrical connections and components for broken or loose wires. KS-250 CONTROL PANEL DOOR (Inside) Rev. Date 1/18/10 Page 24 KS-250 Electrical Schematic Electrical Diagram: Periodically, disconnect machine from power source and check all electrical connections and components for broken or loose wires, and loose screws on contact points. KS-250 CONTROL PANEL BOX C-11 (Vacuum Overload) Rev. Date 1/18/10 Page 25 KS-250 JUNCTION BOX Periodically, disconnect machine from power source and check all electrical connections and components for broken or loose wires. Electrical Diagram: KS-250 Electrical Schematic Rev. Date 1/18/10 Page 26 KS-250 PUMP CABINET Periodically, disconnect machine from power source and check all electrical connections and components for broken or loose wires. Electrical Diagram: KS-250 Electrical Schematic Rev. Date 1/18/10 Page 27 KS-2000 Exploded Parts View UPPER HOPPER AND DRIVE ASSEMBLY See pg. 53 for components See next page for Parts List. Center - Down Rev. Date 1/18/10 Unidirectional Page 28 KS-2000 Exploded Parts List Item# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 18-1 19 20 21 21 22 ---23-A 23-1 23-2 23-3 23-4 23-5 23-5-1 23-6 23-7 23-8 23-9 23-10 23-11 24 25 26 27 29 30 31 32 33 33-1 33-2 33-2A 33-3 33-4 33-5 33-7 33-8 Part# 2502009-1 2502009-A 250503-2 250503-3 250503-5 250503-4 250503-6 250503-9 2502012 40052 150513 FSB120 250503-7 250503-8 250504 561 109811 2502000-1 190 109807 2502028 109809 109808 2502029 ---2502015-A 2502015-1 2502015-2 2502015-3 2502015-4 2502015-5 FSB208 541 FN013 FW007 2530-1 2502015-1-13 2502015-1-14 250523-1 251080-67 251080-51 251080-34 ST354 ELU95-395C-D 109069 543-M-8 1536-A 1536-1-A 1536-2 1536-2A 109066-9 1536-4 1536-5 1536-7 FSB003 Rev. Date 1/18/10 Description Frame, Hopper Btm. Hopper Bottom Assy Agitator, Shredder (1) Agitator, Middle (3) 1 1/4” Felt washer (4) 1 1/4” 2-Bolt Flange Bearing (8) 1 1/4” Bearing Insert (4) 1 1/4” Bearing Guard (4) Chain Guard 1” x 1” Nut (4) Sprocket, #50 Idler (4) 3/4” Shoulder Bolt (3) 1 1/4” Felt Seal (4) 1 1/4” 4-Bolt Flange Bearing (4) #50 Sprocket 20T x 1 1/4” (6) 1/4” x 1/4” x 1” Key (6) #50 Chain, 37 1/2” (2) #50 Chain, 56” Link, Chain, 1/2 #50 NP #50 Chain, 50” #50 Chain, 41” #50 Chain, 55” (Center - Down) #50 Chain, 53 1/2” (Unidirectional) Vibration Isolater (4) 3/8” Lock Washer (8) (Not Shown) 3/8” Nut (8) (Not Shown) 3/8” Flat Washer (4) (Not Shown) Hopper, Top Assy Hopper Extension Door, Right Hopper Door, Left Hopper Door Latch, Upper Swing (2) Door Latch, Upper Swing (Top) Thunbscrew, 5/16” x 1” Hinge Pin (4) 5/16” Wing Nut 5/16” Flat Washer J-Bolt Door Latch, Swing - Lock, Left Side Door Latch, Swing - Lock, Right Side Limit Switch (2) Latch, Panel Box (2) (Not Shown) Rain, Cover (Lexan) Panel Box Guard, Splash Cord, Remote Control, Complete Style D 150 Ft. Cord, #18-3 (SJ) x 150 Ft. Plug, #509-1215 Style D Hand Pendant, Remote Control, Complete Cover, Hand Pendant Switch Insulator (2) Insulator Strip (2) Switch, Toggle (DPDT) Cord Restraint, 3/8” Housing, Switch Clip, Belt Machine Screw, 6-32 x 1/4” Round Head (4) (Not Shown) Page 29 KS-2000 Exploded Parts View LOWER BASE UNIT ASSEMBLY See pg. 55 for components See next page for Parts List. Rev. Date 1/18/10 Page 30 KS-2000 Exploded Parts List Item# Part# 1 2502002 2 151010-Assy 3 -4 541 5 FSB080 6 2502007-A 6-1 2502007 6-2 543-M-75 7 2502005 8 2502025-A 9 2502023 10 -11 2502021 12 S-2000-2-A 12-1 S-2000-2 12-2 S-2000-10 12-3 S-2000-9 12-4 517-7 12-5 8036-2 13 S-2000-5 14 2502004-1 15 4507 16 2502001-A-R1 16-1 2502001-1-R1 16-2 9032-3 16-3 9032-5A 16-3-1 9032-6 16-3-2 9032-5 16-3-3 9032-4 16-4 250503-8 16-5 250503-7 17 8037 18 448 19 150513 20 FSB120 21 40052 22 250505-1 23 562 24 S-2000-4 25 109019-9 26 RM-OTH095-MI 27 339A 28 2502030 29 ST349 30 ST348 31 ST250-7 32 2530-1 33 FW007 34 FN011 35 FN014 36 2502002-A 37 2502033 38 2502034 39 KS341 Rev. Date 1/18/10 Description Base Frame Transformer Assy, 10 KVA Rubber Washers Hinge Pin (2) 5/32” x 5/8” Roll Pin (2) Motor Assy, 3 H.P. 3-Phase Motor 3 H.P. 3-Phase Cord Conduit 1/2” (3 feet) Reducer, Gearbox Sprocket #50 40T x 22T x 1 3/8” Sprocket #50 25T x 1 3/8” Key, 5/16” x 5/16” x 2 3/8” Bracket, Gear Reducer Shredder Box Assy Shredder Box Agitator, Shredder Box, Long Agitator, Shredder Box, Short 1” Felt Seal (4) Bearing 1” 2-Bolt (4) Slidegate (KS250, S-2000) Crankrod w/Handle Bracket Handle, Crankrod Airlock Assy Airlock Chamber Shaft, Airlock, 27 5/8” Long Seal Assy, Airlock 20” (6) Top Plate, 20” (6) Seal, Airlock Rhinohyde, 20” (6) Base Plate, 20” (6) 4-Bolt 1 1/4” Bearing (2) Seal, Felt, Airlock 1 1/4” (2) Sprocket, #50 11T x 1” (2) Key 3/16” x 3/16” x 7/8” (2) Sprocket #50 Idler (3) 3/4” Shoulder Bolt (3) Nut (3) Sprocket, #50 25T x 1 1/4” (2) Key 1/4” x 1/4” x 1 1/4” (2) Spacer, Airlock Idler Bracket Hose, Radiator, 3” x 23” 3” Hose Clamp (2) Clamp, Hose, 3” w/wing nut Block, Hold Down, Top Block, Hold Down, Bottom Track, Mounting Latch Bolt, 2” Bent 5/16” Flat Washer (2) 5/16 - 18 Nut, Hex (2) 5/16 - 18 Lock Nut (2) Bracket, Soft Start Box for 30 Amp Soft Start Box for 16 Amp Soft Start Bushing Reducer, 4” to 3” {(2502004-2) 16” Slidegate: No longer used as of 2-18-05} {(2502001-A) 16” Airlock Assy: No longer used 2-18-05} {(2502001-1) 16” Airlock Chamber: No longer used 2-18-05} {(209031-6) Shaft, Airlock, 23 1/2”: No longer used 2-18-05} {(209031-8-Assy) Seal Assy, Airlock 16” (6): No longer used 2-18-05} {(209031-9) Top Plate, 16” (6): No longer used 2-18-05} {(209031-8M) Seal, Airlock Rhino., 16” (6) No longer used 2-18-05} {(209031-7) Base Plate, 16” (6): No longer used 2-18-05} {(517-6) 4-Bolt 1” Bearing (2): No longer used 2-18-05} {(517-7) Seal, Felt, Airlock 1” (2): No longer used 2-18-05} Page 31 R-500 Exploded Parts View See pg. 53 for components CANISTER LOWER HOPPER & BASE See next page for Parts List. Rev. Date 1/18/10 Page 32 R-500 Exploded Parts List Item# 1 2 2-1 5 6 7 8 9 10 11 12 13 14 14-1 14-2 14-3 15 16 17 18 18-1 18-2 19 20 21 21-1 21-2 21-3 21-4 21-5 21-6 22 23 24 25 26 26-1 27 29 30 31 32 33 34 34-1 35 36 37 38 39 Part# 250512 250512-3 250540 250503-5 250503-4 250503-6 250515 562 250520 FSB120 150513 40052 250514-A 250514-1 250509-A2 250522 S-50BS14-A 561 250500-1 250523-1 126-B 18-3 SJ FSB080 541 250530-A 150523-3 150523-7 150523-6 250530-A1-1 18-3 SJ 1538 150523-4 150523-5 250527 250513-4 250513-4-4 250513-2 250512-28 250513-6 H435 341 340 513-R3 250503-A 250503-1 250517 250503-2 250503-3 250503-9 250503-7 Rev. Date 1/18/10 Description Canister, (Frame w/latches) Backing Screen, Canister Mesh, Stainless Steel Washer, Felt 3 1/2” O.D. x 1 1/8” (5) Flange, 1 1/4” (10) Bearing Insert 1 1/4” (5) Sprocket, #50 60T x 1 1/4” Key 1/4” x 1/4” x1 1/4” (3) Guard, Chain 3/4” Shoulder Bolt Sprocket, Idler #50 x 5/8” Nut, 1” x 1/2” (Plated) (4) Motor & Cord Assy Motor, 1 H.P., 3-Phase Cord & Plug Assy Plug, 3-Phase, 20 Amp Sprocket #50 14T x 1” Key, 1/4” x 1/4” x 1” (6) Chain #50 x 66” Limit Switch Plug, (5666C) Wire, 18-3 SJ, 2 1/2ft Long 5/32” x 5/8” Roll Pin (4) Hinge Pin (4) Bin Level Indicator Assy Bin Level Indicator Flange Assy w/Gasket Paddle, Indicator Connector (4579C) Wire, 18-3 SJ 16ft Long (2) Plug NEMA# L5-15P Nipple, Pipe 1/4” x 3 1/2” Coupling, Pipe 1/4” Bushing Reducer, 1 1/4” - 1/2” PVC Agitator, Vertical Wiper, Vertical Agitator Wiper Strip, 2-PLY Brush, Wiper Plate, Wiper Hose, Flex-Thane, 6”, 36” long 6” Hose Clamp (4) 4” Hose Clamp (2) Reducer, Gear Hopper Assy, #500 ST-250 Hopper, #500 ST-250 Guard, Chain Agitator, Shredder (1) Agitator, Standard (2) Guard, Bearing 1 1/4” (3) Seal, Felt 1 1/4” (3) Page 33 R-500 Exploded Parts List Part# Item# 250503-8 40 250504 41 250501 42 2530-1 43 FW007 44 FN011 45 FN014 46 250509-A 47 150509-1 47-1 250509-A2 47-2 250522 47-3 250529 48 250505-A 49 250518-R1 50 109810 51 250506 52 109805 53 250508-1 54 4507 55 250508-3 56 250508-4 57 250508-5 58 250508-3-2 59 250507-A 60 250507-1 60-1 209031-9 60-2 209031-8M 60-3 60-3A 209031-8-Assy 209031-7 60-4 209031-6 60-5 517-7 60-6 517-6 60-7 339A 61 H319 62 250501-1A 63 63-1 250501-1A-1-A 250501-1A-2 63-2 250501-1A-3 63-3 250501-1A-4 63-4 250521 64 150510 65 2502030 66 250528 67 250535 68 250539 69 250532 70 250300-13 71 ST349 72 ST348 73 250534 74 209031-10 75 76 RM-OTH014-MI Rev. Date 1/18/10 Description Bearing Flange 4-Bolt, 1 1/4” (3) Sprocket, #50 20T x 1 1/4” (3) Base, 500 (ST250) Latch Bolt, 2” Bent (2) 5/16” Flat Washer (2) 5/16 - 18 Nut, Hex (2) 5/16 - 18 Lock Nut (2) Motor & Cord Assy 2 Hp., 3-Phase Motor, 2 H.P., 3-Phase Cord & Plug Assy Plug, 20 Amp, 3-Phase Reducer, Gearbox (After 10-23-00) Sprocket, #50 25T x 26T x 1 1/4” Bracket, Reducer (After 10-23-00) #50 Chain, Inside Agitator, 64 1/2” #50 Chain, Airlock Drive, 48 1/2” #50 Chain, Outside Agitator, 40” Slidegate, (Stainless Steel) Handle, Crankrod Crankrod w/handle bracket Arm, Slidegate Adapter, Crankrod, Slidegate Support, Handle, Crankrod Airlock Assy Chamber, Airlock Plate, Top, 16” (6) Seal, Airlock, Rhinohide, 16” (6) Seal Assy, Rhinohide, 16” (6) Plate, Base f/16” Airlock Shaft, Airlock 23 1/2” Seal, Felt, Airlock 1” (2) Bearing, 4-Bolt, 1” (2) 3” Hose Clamp (6) Hose, Flexhaust 3” x 50” Pointer Body Assy. Coil Spring w/nut Cover, Coil Spring Pointer Indicator Pulley, Cable Cable, 27” Sprocket #50 25T x 1” (2) 3” Hose Clamp w/Wing Nut Bracket, Airlock Mount, Check Valve, Directional 3” Check Valve Inlet, Air, 3” Dia. x 1 1/4” & 1 1/2” bypass outlets Adapter, Hose, Male, 3” Dia. Block, Hold Down, Top Block, Hold down, Bottom Elbow, Sweep, 3” w/Bolt Clamps Airlock Spacer, 16” Felt Adhesive, 1” wide x 1/8” thick, 12 Ft. Long Page 34 V-15 Exploded Parts View V-15 VACUUM See next page for Parts List. Rev. Date 1/18/10 Page 35 V-15 Exploded Parts List Item# Part# Description 1 250358 Box Enclosure, F/Under Truck Vacuum 2 250360 Door, Vacuum Box Enclosure 3 250361 Frame, Mounting, Vacuum Box 4 340 Clamp, Hose 4” (2) 5 H420 Hose 15 1/2ft.,4” Spiralite 6 250308-2 Cover Plate, Fan Chamber 7 250307 Fan, 16” 8 250306 Spacer, 2Ply Rubber 9 250308-1-R1 10 250359 Grill, Return Air 12” x 14” 11 250365 Milled Bearing, Link Belt (FU324) 12 250367 Bearing Support, 6 1/2” x 6” x 2” 12-1 FSB084 Bolts 1/2 -13 x 1 1/2” Hex HD (2) 12-2 FW020 1/2” Lock Washer 12-3 FW012 1/2” Flat Washer SAE 13 250355 Bearing, Link Belt (FU324) 14 150310 Pin, Cotter, 1/8” x 2” 15 FN034 Slotted Nut, 1”-14 16 109080 Key, 1/4” x 1/4” x 2 1/8” 17 250345-R2 18 250312 Pulley, (4P3V36) 15 H.P. Motor 19 250309 Bushing,15 H.P. Motor (P1 1 1/2”) 20 250368 V-Belt, 4 Band (4/3VX315) 21 250362 Lid, Vacuum Box Enclosure 22 250315 Motor Mount Assy 23 250321-1 24 250332 Key, 3/8” x 3/8” x 2 7/8” 25 250349 Pulley, (4Q3V69) 26 250351 Bushing 15 H.P. (Q1 1 5/8”) 27 543-M-75 1/2” Flex Conduit 28 543-M-25 1/2” 90 Conduit Connector (Not Shown) 29 ST342 30 250348-1 Rev. Date 1/18/10 Chamber, Fan, 16” Shaft, Fan, 14”, Vac. Chamber 15 H.P., (used on 16” fan) Motor 15 H.P., 3 Phase (3500 rpm) Clamp, Hose, Wall (4) Insert, Bearing,1 1/2" (2) (Replacement) Page 36 B-10 Exploded Parts View B-10 BLOWER See next page for Parts List. Rev. Date 1/18/10 Page 37 B-10 Exploded Parts List Item# Part# 1 250300-9-R1 2 250300-14 Mounting Frame, Blower Box 3 250300-17 Mount, Base, Positive Pressure Blower System 4 150315-1 Mount, Motor 5 250300-8 Motor 10 H.P., 3 Phase 1750 r.p.m 6 250300-1 Blower, Rotary Positive Pressure Blower (4007) 7 -- Key, 5/16” x 5/16” x 2 3/8” 8 449-R1 Key, 3/16” x 3/16” x 1 7/8” 9 250300-3 Pulley, 2Q3V80 10 250300-4 Pulley, 2Q3V69 11 250300-5 Bushing, Q1 1 3/8” 12 250300-6 Bushing, Q1 7/8” 13 250300-21 2V-Belt, 56” (2/3VX560) 14 250300-2-R1 14-1 -- 14-2 81-1063 15 250300-11 Nipple, 3” Close 16 250300-12 Elbow, 3” 90 17 8052 Pressure Relief Valve 18 250300-13 Adapter, Male Hose Description Blower Box, Aluminum (22” x 24” x 48”) Silencer Assy., Intake Filter (Blue) (After 5/7/01) Cover, Filter Filter for 250300-2-R1 (Blue) 19 RM-OTH095-MI Hose, Radiator, 3” x 26” 20 339A Clamp, Hose, 3” (28) 21 RM-OTH095-MI Hose, Radiator, 3” (4” Long) (6) 22 RM-OTH073-MI Aluminum Tubing, 3” Dia. (4ft-6ft Long) 23 RM-OTH073-MI Aluminum Tubing, 3” Dia. (29” Long) 24 200300-20 25 ST361 Bracket, Support, Blower Box 26 KS335 Bracket, Tubing Support (Under Truck) (Not Shown) 27 250359 Grill, Return Air 12” x 14” Rev. Date 1/18/10 Elbow, Blower Box, 90 (4) Page 38 Filter Box Exploded Parts View FILTER BOX Item# Part# Description 1 FB251-1 Box, Filter 2 FB250-2 Bag, Filter 3 FB251-2 Overhead Tube, f/Filter Box 4 H435 Hose, Flex-Thane, 6”, 36” long 5 341 Clamp, Hose, 6” (4) 6 150522 Rev. Date 1/18/10 Clamp, Hose, 6” w/wingnut Page 39 Air Relief Valve Exploded Parts View AIR RELIEF VALVES Item# Part# Description 1 ST250-1 Bracket, Gauge 2 ST250-2 Clamp, Gauge Bracket, Short 3 ST250-3 Clamp, Gauge Bracket, Long 4 ST250-5-2 Ball Valve, 1 1/4” 5 ST250-5-1 Nipple, Pipe, 1 1/4” x 5” (2) 6 ST250-5-3 Elbow, 90 Degree, 1 1/4” (2) 7 ST250-5-4 Adapter, 1 1/4” Barb (2) 8 ST250-6-2 Ball Valve, 1 1/2” 9 ST250-6-1 Nipple, Pipe, 1 1/2” x 2” (2) 10 ST250-6-3 Elbow, 90 Degree, 1 1/2” (2) 11 ST250-6-4 Adapter, 1 1/2” Barb (2) 12 ST250-5-6 Pointer Indicator 13 RM-OTH083-MI Hose, 1 1/4” Spiralite (12” Long) 14 RM-OTH082-MI Hose, 1 1/2” Spiralite (12” Long) 15 RM-OTH083-MI Hose, 1 1/4” Spiralite (9 1/2ft Long) 16 RM-OTH082-MI Hose, 1 1/2” Spiralite (9ft Long) 17 ST345 Clamp, Hose, 1 1/16” - 2" (14) 18 KS345 Mount, Pressure Gauge 19 299-1 Gauge, Pressure, 0-10 PSI Rev. Date 1/18/10 Page 40 Water Pump Assembly Exploded Parts View PUMP ASSEMBLY Description Item# Part# 1 C-2 2 M-03 M-3 Diaphragm Pump 3 P-1B Street Tee, 3/8” (2) 4 P-1C Bushing, 1/4” to 3/8” (2) 5 P-1D Pressure Guage, 0-600 P.S.I 6 P-1G Close Nipple, 3/8” 7 P-1H Coupler, Female, QD, 1/2”, P&M Assy (2) 8 G-P-16 9 P-1J 10 P-1K 11 P-2C-ASSY 12 Ball Valve, 1/4”, Comm, WC, IWS Item# Part# Adapter, 1/2” to 3/8” 19 W-2 Pressure Regulator, 3/8” 20 Motor, 1 H.P. Assy, 1-Phase 21 IWS-4C Solenoid Valve, 300 PSI 583 Motor, 1 H.P. 120/230 V., 60 Hz. 22 IWS-38 Elbow, 1/4” Brass (2) 12-1 585 Motor, 1 H.P. 120/230 V., 50 Hz. 23 IWS-32 Male Connector 13 P-3A Base, Pump Assembly 24 IWS-4D Solenoid Coil, 120V 14 127 Plug, NEMA# 5-15P 25 391N-A-2 1/2” Liquid Tite Connector 15 P-8-ASSY Cord Assy (Includes: Cord & Plug) 26 18-3SJ Cord, 18-3(SJ) (33” Long) 16 1536-3 Switch, Toggle (SPST) 27 40050 Clip “Z”, Filter Frame 17 1536-6 Switch Guard (Cone) 28 348D-DIA Diaphragm (Not Shown) 18 P-14 Nipple, Male, QD, 1/2” MPT 29 348D-KIT Diaphragm Repair Kit (Not Shown) Rev. Date 1/18/10 Elbow, 1/2” Brass, Street Description Coupler, Female, QD, 1/4” ST250-IWS-3 Mounting Bracket, IWS Page 41 Water Tank Hose Reel Exploded Parts View WATER TANK HOSE REEL Item# 1 2 3 Part# Description 250700-1-25-6 Mount, Hose Reel, Water Tank 250700-35 Hose Reel, Water Tank 250700-1-25-3 Handle, Hose Reel 4 FSB189 Carriage Bolt, 5/16 - 18 x 4” 5 FN038 Lock Nut, 5/16 - 18 6 250700-1-25-9 Cap, w/Nut 7 250700-9 8 250700-3-R1 Fitting, Hose End (2) 9 HH-3/8-SP Terminator Hose, Yellow, 3/8” (200ft. Long) (200ft. started on truck KS128) Rev. Date 1/18/10 Nipple, (Female) QD, 1/4” (2) Page 42 Pump Cabinet Exploded Parts View PUMP CABINET Connection Hose Connects Water Pump to IWS See next page for Parts List. Rev. Date 1/18/10 Page 43 Pump Cabinet Exploded PartsView PUMP CABINET See next page for Parts List. Rev. Date 1/18/10 Page 44 Pump Cabinet Exploded Parts List Item# 1 1-1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 17-1 18 19 20 21 22 23 24 25 26 27 28 29 30 31 31-1 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 Part# 250700-1-36 250700-1-30 250700-23-R1 250700-24-R1 250700-10 250700-28 250700-1-4 250700-1-11 HH-1/2 250700-1-3 250700-1-18 HH-1/2 250700-1-7 250700-1-6 HH-1/2 G-33 P-1H 250700-1-12 250700-1-12-1 250530-2 HH-1/2 P-1P 250700-1-27 G-26 250700-1-28 250700-1-2 250700-1-21 250700-16 HH-3/4 250700-25 250700-2-1 250700-2-2-R1 RM-OTH029-MI RM-OTH029-MI 250700-21 250700-26 341 251080-68 250700-31 250700-29 250700-27 ST347 250700-9 250700-3-R1 HH-3/8-SP 250700-22 250700-1-9 HH-3/4 IWS-25E Rev. Date 1/18/10 Description Bladder, Water Tank Encasement, Water Tank Enclosure, Side Enclosure, Top Flashing, Side (2) Support Bracket, Water Tank Hose Barb, 1/2” - 1/2” (7) Clamp, Hose, 1/2” (16) Heater Hose, 1/2” (20” Long) Valve, Gas, 1/2” (3) Valve Hold Down, Pump Cabinet Heater Hose, 1/2” (24” Long) Nipple, Hex, 1/2” x 1 1/2” (2) Nipple, Brass 1/2” Close Heater Hose, 1/2” (10 1/2” Long) Hose Barb, Female, 1/2” - 1/2” Coupler, (Female) QD, 1/2” Filter Assy, 3/4” Filter Screen Bushing, Brass Hex, 3/4” - 1/2” Heater Hose, 1/2” (9 1/2” Long) Nipple, Male, FPT, 1/2” Valve Hold Down, 3/4” Line Hose Barb, 3/4” - 3/4” (3) Elbow, 3/4”, 45 degree Valve, Gas, 3/4” Nipple, 3/4” x 2” Coupler, Brass, 3/4” FH-3/4 FP Heater Hose, 3/4” (23 1/2” Long) Bracket, Overflow Mounting Plate, Thermostat Outlet Bracket, Heater Fan Tubing, Vinyl, 1/2" I.D. (28” Long) (2) Tubing, Vinyl, 1/2" I.D. (48” Long) Elbow, 1/2”, 90 Degree, Plastic (2) Flashing, Bottom Clamp, Hose, 6” Heater & Fan, Pump Cabinet Electrode, 750 Watt Heater Enclosure, Side,Water Tank Enclosure, Top, Water Tank Nipple, 1” x 8” Galv. (Not Shown) Nipple, (Female) QD, 1/4” (4) Fitting, Hose End (2) Terminator Hose, Yellow, 3/8” (24” Long) Thermostat, Water Tank Elbow, 3/4", 90 Degree Heater Hose, 3/4” (60” Long) Water Line, 1/4" x 30' w/Swivel Page 45 Cummins Generator Assembly Exploded Parts View GENERATOR ASSEMBLY Fuel Pump located under front of truck See next page for Parts List. Rev. Date 1/18/10 Page 46 Cummins Generator Exploded Parts List Item# Part# 1 ST301-1B 2 -- 3 ST304 4 ST304-2-1-R1 Cover, Access Hole 6 ST301-7 Base, Engine Cover 7 RM-OTH203-MI Fuel Line, 5/16” (Supply) 8 RM-OTH202-MI Fuel Line, 1/4” (Return) -- ST301-13 Hose Barb, Brass, 5/16” (Not Shown) (Fuel Line) -- ST301-14 Hose Barb , Brass, 1/4” (Not Shown) (Return Line) 9 ST301-16 Fuel Pump 10 ST301-17 Clamp, Hose, 7/32” - 5/8” 11 251080-30 Connector, 1”, 90 12 251080-31 Conduit, Flexible 1”, 12 Ft 13 ST301-8-B Muffler 14 RM-OTH097-MI Pipe, Exhaust, Flex, 3”, 4 Ft 15 RM-OTH022-MI Heat Wrap, f/Generator, 60 Ft 16 2502001-1-1 17 ST301-19 Adapter, Exhaust, (Straight) 18 ST301-18 Pipe, Tail Exhaust (Elbow) 5” 19 ST301-30 Clamp, 3” Muffler 20 339A Clamp, Hose, 3” 21 ST353 Guard, Muffler 22 ST301-10 Door, Louver, Generator, 36” x 48” 23 ST301-2 Battery, Generator, 700 CCA 24 RM-OTH002-BK Wire, 2 Ga. Black, 5 Ft 25 RM-OTH002-RD Wire, 2 Ga. Red, 7Ft 26 ST301-4 Connector, Wire, Battery (2) 27 ST301-3 Connector, Battery Terminal (2) Rev. Date 1/18/10 Description Generator, EPS, 60 KW Controls, Engine Cover, Engine, Generator Elbow, 3”, 90 Page 47 John Deer Generator Assembly Exploded Parts View GENERATOR ASSEMBLY Fuel Pump located under front of truck See next page for Parts List. Rev. Date 1/18/10 Page 48 John Deer Generator Exploded Parts List Item# Part# 1 ST301-1 Generator, 60 KW 2 -- Controls, Engine 3 ST250-4 Bracket, Engine Control 4 ST304 Cover, Engine, Generator 5 ST304-2-1-R1 Cover, Access Hole 7 -- Base, Engine Cover 8 RM-OTH203-MI Fuel Line, 5/16” (Supply) 9 RM-OTH202-MI Fuel Line, 1/4” (Return) -- ST301-13 Hose Barb, Brass, 5/16” (Not Shown) (Fuel Line) -- ST301-14 Hose Barb, Brass, 1/4” (Not Shown) (Return Line) 10 ST301-16 Fuel Pump 11 ST301-17 Clamp, Hose, 7/32” - 5/8” 12 251080-30 Connector, 1”, 90 13 251080-31 Conduit, Flexible 1” 14 ST301-8 Muffler 15 RM-OTH022-MI Heat Wrap, f/Generator, 60 Ft 16 -- Pipe, Tail Exhaust (Elbow) 5” 17 -- Elbow, 4”, 90 18 ST301-20 19 339A 20 ST301-5 Clamp, Band 21 ST301-10 Door, Louver, Generator, 36” x 48” 22 ST353 23 ST301-2 24 RM-OTH002-BK Wire, 2 Ga. Black, 5 Ft 25 RM-OTH002-RD Wire, 2 Ga. Red, 7 Ft 26 ST301-4 Connector, Wire, Battery (2) 27 ST301-3 Connector, Battery Terminal (2) 28 ST301-15 Box, Battery 29 ST301-7-7 Holder, Battery Rev. Date 1/18/10 Description Clamp, 5” Muffler Clamp, Hose, 3” Guard, Muffler Battery, Generator, 700 CCA Page 49 PTO Generator Exploded Parts View POWER TAKE OFF Item# Part# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 ST301-1C ST301-8 ST359 ST301-37 251080-30 251080-31 543-M-75 543-M-18 ST301-38 ST301-39 ST301-40 ST301-42 KS260-PTO-3 KS260-PTO-2 ST301-33 ST301-36 ST301-34 KS353-10 Rev. Date 1/18/10 Description Generator, (PTO) Mount, Generator, PTO Mount, Leveling, Generator Enclosure, Generator Conduit Connector, 90 Flexible Conduit, 1”, 28 ft. long Flexible Conduit, 1/2”, 29 ft. long Conduit Connector, Straight, 1/2” Fan, Exhaust Bracket, Mounting, Fan Vent Cover Bushing, 2 7/8” Pulley, 4C85E (After 10-12-06) Pulley, 4C100E (After 10-12-06) Bushing, 2 1/4” Collar, Single Split, 2 1/4” (4) Bearing, 2 1/4” (2) Shaft, 2 1/4” Dia., 30” long Item# Part# 19 20 21 22 23 24 25 26 KS260-PTO-1 KS348 KS347 KS346 580 541 KS353-13 KS344 992 27 Description Belt, Banded, 4/CX105 (After 10-12-06) Bracket, PTO Cover, 29 5/8” Long Bracket, PTO Cover, 34 3/4” Long Bracket, PTO Cover, 60 3/4” Long Bracket, Hinge (3) Pin, Hinge (3) 3/8” x 1/2” Key Bracket, Hour Meter (Not Shown) Hour Meter (TM4594) ( Not Shown) Note: Item 26 & 27 are optional units for trucks w/o a digital hour meter. Page 50 Hose Reel Exploded Parts View GENSET HOSE REELS Item# Part# 1 ST328-F Frame, Hose Reel, Wall Mount (2) 2 ST328-R Reel, Hose, 36” x 24” Wide 3 ST329-R Reel, Hose, 44” x 24” Wide 4 328-C-M-H Collar, Hose Reel (2) 5 FSB036 5/16 -18 x 5/8” Hex (4) 6 H319 Hose, Flexhaust, 3” x 50’ (3) 7 H400 Hose, Smooth Bore, 4” x 50’ (3) 8 380 Tube, Connector, 3” x 5” (2) (Not Shown) 9 381 Tube, Connector, 4” x 5” (2) (Not Shown) 10 250600 11 250600-1 12 359 Reducer Tube, 3” to 2 1/2” 13 H419 Hose, Vaccuflex, 12 1/2’ Rev. Date 1/18/10 Description Wand, Vacuum, 4” x 4’ Coupler, 3” PVC Page 51 Hose Reel Exploded Parts View POWER TAKE OFF GENERATOR HOSE REEL Item# Part# Description 1 KS337 Wall Mount, Hose Reel 2 KS333 Reel, Hose, 90” x 12 1/2” Wide 3 328-C-M-H 4 FSB036 5 H319 Hose, Flexhaust, 3” x 50’ (3) 6 H400 Hose, Smooth Bore, 4” x 50’ (3) 7 380 Tube, Connector, 3" x 5" (2) (Not Shown) 8 381 Tube, Connector, 4" x 5" (2) (Not Shown) 9 250600 10 250600-1 11 359 Reducer Tube, 3” to 2 1/2” 12 H419 Hose, Vaccuflex, 12 1/2’ Rev. Date 1/18/10 Collar, Hose Reel 5/16 -18 x 5/8” Hex (2) Wand, Vacuum, 4” x 4’ Coupler, 3” PVC Page 52 Electrical Box Exploded Parts View Item# Part# Description 80-1 251080-A-R1 Electrical Assy w/oActuator 80-2 251080-B-R1 Electrical Assy w/Actuator 80-3 251080-1 80-4 504-2 Kill Switch Button (2) 80-5 504-1 Kill Switch Contactor (2) 80-6 151080-4 Disconnect Switch 80 Amp (1) 80-7 251080-2 12 Terminal Grounding Bar 80-8 151080-6 Alarm 24 Volt 80-9 KMCS-101 Breaker Decal 80-10 KMCS-102 Operating Controls Decal 80-11 251080-35 Amber Pilot Light 1/2” Neon 80-12 251080-36 Green Pilot Light 1/2” Neon 80-13 543-M-59 Push Button (Green) 80-14 543-M-22 4 Pos. Selector Switch (2) 80-15 251080-3 3 Pos. Selector Switch 80-16 543-M-52 2 Pos. Selector Switch 80-17 543-M-16 Contactor, KA-3 (9) (Not Shown) 80-18 543-M-54 Contactor, KA-2 (Not Shown) 80-19 543-M-15 Contactor, KA-1 (3) (Not Shown) 80-20 251080-4 Weatherproof 2-Gang Cover Plate 80-21 251080-5 Heavy Duty Duplex 15 Amp (3) 80-22 543-M-2 Receptacle, RC Plug #509-1050 (1) 80-23 KMCS-024 80-24 109066-9 Switch, Toggle,(DPDT) 80-25 251080-6 Circuit Breaker Door 80-26 251080-7 Circuit Breaker Door Plexiglass 80-27 251080-8 Circuit Breaker Top Protector (Not Shown) 80-28 251080-9 Circuit Breaker Bottom Protector (Not Shown) 80-30 251080-51 Cover, Plexiglass, Panel Box (See Page 29) 80-31 251080-11 Circuit Breaker Standoff Electrical Plate, Mounting Panel MADE IN U.S.A. Electrical Maintenance KS-250 DRY MODE RECYCLE MODE VACUUM MACHINES VERTICAL AGITATOR REMOTE CONTROL OUTLET RECYCLE MACHINE Remote Control Outlet Decal 80-32 RM-DINRAIL-A 1 3/8” Din Rail 80-33 151080-49 1 3/8” Din Rail Clamp (8) 80-34 251080-12 3-Pole 60 Amp Supplementary Protector 80-35 251080-65 2-Pole 20 Amp Supplementary Protector 80-36 251080-14 1-Pole 15 Amp Supplementary Protector (1) 80-37 251080-15 1-Pole 20 Amp Supplementary Protector (2) 80-38 251080-16 1-Pole 1 Amp Supplementary Protector 80-39 251080-17 1-Pole 2 Amp Supplementary Protector Rev. Date 1/18/10 Level Power Kill Switch Level On/Off Page 53 Electrical Box Exploded Parts View Description Item# Part# 80-40 251080-56 1-Pole 63 Amp Supplementary Protector 80-41 251080-19 2-Pole Power Distribution Block 80-42 251080-20 3-Pole Power Distribution Block 80-43 251080-21-R1 120 Volt 5 Hp Starter 80-44 251080-22-R1 24 Volt 5 Hp Starter (2) 80-45 251080-53-R1 24 Volt 10 Hp Starter 80-46 251080-23-R1 1.6 - 2.5 Amp Thermal Overload 80-47 251080-24-R1 4-6 Amp Thermal Overload 80-48 251080-25-R1 2.5-4 Amp Thermal Overload 80-49 8021-15-R1 9-13 Amp Thermal Overload 80-50 251080-26 NEMA Size 2 Starter 80-50A 251080-49 Thermal Overload Relay 80-50B 251080-50 Thermal Units (3) 80-51 543-M-41 8 Pin Sockets (5) 80-52 543-M-39 Pre-Alarm Relays (3) 80-53 543-M-51 Cube Relay 120 Volt (2) 80-54 543-M-69 Solid State Relay 120 Volt 80-55 1530-D MADE IN U.S.A. Electrical Maintenance KS-250 DRY MODE RECYCLE MODE VACUUM MACHINES VERTICAL AGITATOR REMOTE CONTROL OUTLET RECYCLE MACHINE Transformer, 4 Amp 80-56 RM-CHL001-MI Wire Channel 1” x 2” 80-57 RM-COV001-MI Wire Channel Cap 1” 80-58 RM-DINRAIL-B 3/4” Din Rail 80-59 151080-63 3/4” Din Rail End Clamp (White) (6) 80-60 151080-61 Small Terminal Block 30 Amp (43) 80-61 151080-62 Large Terminal Block 60 Amp (3) 80-62 151080-33 Receptacle NEMA #L16-20R (2) 80-63 132-B Receptacle NEMA #6-15R 80-64 1542-A Receptacle NEMA #L5-15R 80-65 251080-28 Receptacle Flanged NEMA# L6-15P 80-66 543-M-18 1/2” Straight Conduit Connector (7) 80-67 543-M-25 1/2” 90 Conduit Connector (4) 80-68 251080-29 1” Straight Conduit Connector 80-69 151080-67 1/2” 45 Conduit Connector 80-70 251080-31 1” Flex Conduit 80-71 543-M-75 1/2” Flex Conduit 80-72 251080-32 12 ft. 7 pin Female Mini-Connector Cord 80-73 251080-33 12” 7 Pin Male Mini-Receptacle 80-74 1560 80-75 1561 80-76 KMCS-012 Rev. Date 1/18/10 Level Power Junction Box (1) Junction Box Lids (1) Kill Swit ch Level On/ Off Kill Switch Decal Page 54 Electrical Box Exploded Parts View Description Item# Part# 80-77 KMC-103 “Level On/Off” Decal 80-78 KMC-104 “Level Power” Decal 80-79 KMCS-105 “Vertical Agitator” Decal 80-80 KMC-106 “Vacuum” Decal (Not Shown) 80-81 KMCS-107 “Recycle Machine” Decal 80-82 KMCS-108 “Caution Door Must Be Closed” Decal (Not Shown) 80-83 251080-34 Panel Box 80-84 2502033 Box for 30Amp Soft Start 80-84 2502034 Box for 16Amp Soft Start 80-85 2502031 Soft Start (30Amp) 80-85 2502032 Soft Start (16Amp) 80-86 2502031-Assy Soft Start Assy (30 Amp) 80-86 2502032-Assy Soft Start Assy (16 Amp) 80-87 251080-60 Cord Connector, Liquid-Tite Brown 80-88 250523-1 Limit Switch, Miniature (2) 80-89 251080-48 Outlet Box (3) 80-90 251080-47 Duplex Outlet Cover 80-91 42528 80-92 251080-46 Outlet Cover 80-93 250700-2-4 Bracket, Outlet 80-94 433-F 12 Amp Reset 80-95 151015 Retainer Clips (2) 80-96 2511560-R Junction Box, Recycle 80-97 250700-2-6 Receptacle, Single, NEMA# 5-15R 80-98 250700-2-7 Cover Plate, Receptacle 80-99 KMC-125 American Flag Decal 80-100 KMCS-120 Electrical Maintenance Decal MADE IN U.S.A. Electrical Maintenance KS-250 DRY MODE RECYCLE MODE VACUUM MACHINES VERTICAL AGITATOR REMOTE CONTROL OUTLET RECYCLE MACHINE Receptacle NEMA #5-15P Level Power Kill Switch Rev. Date 1/18/10 Level On/Off Page 55